Method of Forming a Temporary Wall System

ABSTRACT

A method of forming a temporary wall system is disclosed. The method includes attaching a track to a floor and attaching cover panels including tongue and groove systems to the front and the rear surfaces of separate insulation layers to form several wall panels. In one embodiment, the method includes attaching the wall panels to each other via the tongue and groove systems disposed on the cover panels to form a wall and then mounting the wall onto the track to form an upstanding temporary wall. In another embodiment, the method includes first mounting the wall panels onto the track and then attaching the wall panels to each other via the tongue and groove systems while on the track to form the wall.

FIELD OF THE DISCLOSED TECHNOLOGY

The disclosed technology relates to methods of forming a temporary wall system, more specifically to a method of forming a temporary wall system by attaching a track to floor and ceiling, forming wall panels, and mounting the wall panels on the track.

BACKGROUND OF THE DISCLOSED TECHNOLOGY

Temporary walls or partitions are often used at construction sites, such as renovation or remodeling projects in malls, hotels, office buildings and other public or private venues. These walls provide a safe environment while the renovation or remodeling project is in progress. They may also block dust and noise from entering public spaces on the other side of the wall. Typically, temporary walls or partitions are constructed on site using traditional building materials, such as lumber and drywall or plywood. This is costly, time-consuming and creates debris. Additionally, such temporary walls are difficult to reuse after no longer being needed at a particular location.

Accordingly, there is a need for a method of constructing a temporary wall system that is significantly less time-consuming, requires less materials, creates significantly less debris, is easy to disassemble, and is reusable.

SUMMARY OF THE DISCLOSED TECHNOLOGY

Disclosed herein is a method of forming a temporary wall system, including attaching a track to a floor and ceiling, attaching a first cover panel to a front surface of a plurality of insulation layers, attaching a second cover panel to a rear surface of the plurality insulation layers to form a singular wall panel. The plurality of such singular wall panels are connected, to each other via a tongue and groove system to form a wall that spans the length of the track, and then mounted onto the track. In one embodiment, the track includes a width substantially equal to the width of the wall, such that the track supports the wall therein in an upstanding position.

In some embodiments, the method includes first mounting each singular wall panel onto the track and then attaching each of the plurality of wall panels to each other via the tongue and groove system while on the track to form the wall.

In some embodiments, the track is attached to the floor and ceiling of an area by mounting the track onto the floor and fastening the track with fasteners.

In some embodiments, the first cover panel is sprayed on the entire surface, or substantially the entire surface, of one side with a bulk spray adhesive, the front surface of each of the plurality of insulation layers is also sprayed with a bulk spray adhesive. These are then attached to each other.

In some embodiments, the second cover panel is sprayed on the entire surface of one side, or substantially the entire surface, with a bulk spray adhesive, the rear surface of the plurality of insulation layers (attached to the first cover panel) is sprayed with a bulk spray adhesive. These second cover panel is then attached to the rear surface of the plurality of the insulation layers.

In some embodiments, each of the plurality of insulation layers includes a thermal insulation board including a rigid cellular polyisocyanurate foam core disposed between a first foil facer defining the front surface of insulation layer and a second foil facer defining the rear surface of the insulation layer.

In some embodiments, the first cover panel and the second cover panel each include a first side including a tongue extending along an edge of the first side and an opposing second side including a groove extending along an edge of the second side. The tongue and groove are complimentary in that they mate and fasten with each other.

In some embodiments, the plurality of wall panels are attached to each other by joining the tongue of a first side of a first cover panel and the groove of a second side of a first cover panel in sequential fashion and joining the tongue of a first side of a second cover panel and the groove of a second side of a second cover panel in sequential fashion. The joining of the plurality of wall panels to each other forms the wall.

In some embodiments, the wall is mounted on the track by sliding the wall into the track such that the wall is coextensive with the track.

For purposes of this disclosure, the following definitions are used. “Temporary” is defined as “being designed to be constructed and deconstructed multiple times without structural damage.” “Mount” is defined as “place or fix an object or item in its operating position, and/or to attach the object or item to a support, and/or to arrange the object or item for use or display” “Track” used interchangeably with “rail” and “channel”, is defined as “a receptacle that provides a path on which another object slides along an axis of movement, such as a horizontal axis, the receptacle forming a frame for a wall.” “J-track” is defined as “a track including a pair of side walls or legs, wherein a first side wall includes a height that is less than a height of a second sidewall.” A “wall” is a “partition which partially or fully separates a space into two spaces, at least, where the wall is situated.” “Panel” is defined as “a resilient flat or curved planar structure that forms part of a wall, and/or a board set to cover a part or all of an exterior side of a wall, and/or is co-planar with a wall.” “Insulation” is defined as “material designed by a manufacturer or installer thereof to insulate (prevent passage of heat and/or cold) a wall or room within a building.” “Layer” is defined as “one of a plurality of separable like-kind units.” “Cover” is “a layer thinner than an insulation layer sized to fit over, or substantially fit over, a largest plane of an insulation layer.” “Bulk Spray” is defined as “spray provided in a pressurized container, such as a cylinder, that comes in bulk.” “Coextensive” is defined as “equal or coincident in space or having the same spatial boundaries.” “Upstanding” refers to/is defined as “the positioning of an object or item such that the object or item is vertically or perpendicularly erect or upright relative to the floor.” “Adhesive” is defined as “any substance or material, such as glue, cement, mucilage, or paste, that when applied to one or both surfaces of two separate items binds the surfaces together and resists their separation.”

Any device or step to a method described in this disclosure can comprise or consist of that which it is a part of, or the parts which make up the device or step. The term “and/or” is inclusive of the items which it joins linguistically and each item by itself. “Substantially” is defined as at least 95% of the term being described and/or “within a tolerance level known in the art and/or within 5% thereof. Any device or aspect of a device or method described herein can be read as “comprising” or “consisting” thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flow chart of a method of forming a temporary wall system according to one embodiment of the present disclosed technology.

FIG. 2 shows a flow chart of a method of forming a temporary wall system according to another embodiment of the present disclosed technology.

FIG. 3 shows a front view of a temporary wall system formed according to one embodiment of the present disclosed technology.

FIG. 4 shows a perspective view of a temporary wall system formed according to one embodiment of the present disclosed technology.

FIG. 5 shows an exploded view of the wall system coming together according to a method of forming the temporary wall system in one embodiment of the present disclosed technology.

FIG. 6 shows a cross-sectional view of the wall of the temporary wall system according to one embodiment of the present disclosed technology.

FIG. 7 shows a close-up view of the tongue and groove system of the cover panels joined together to from the wall of the temporary wall system according to one embodiment of the present disclosed technology.

FIG. 8 shows a side view of the track according to one embodiment of the present disclosed technology.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE DISCLOSED TECHNOLOGY

The present disclosed technology provides a method of forming a temporary wall system by mounting a track onto a floor and/or ceiling, attaching cover panels to front and rear surfaces of insulation layers to form wall panels, attaching the wall panels to each other via tongue and groove systems disposed on the cover panels to form a wall, and mounting the wall on the track. The method provides an efficient means for erecting a temporary wall that is both easy to assemble and disassemble, which significantly increases reusability.

Referring now to the Figures, FIG. 1 shows a flow chart of a method of forming a temporary wall system according to one embodiment of the present disclosed technology. FIG. 2 shows a front view of a temporary wall system formed according to one embodiment of the present disclosed technology. FIG. 3 shows a perspective view of a temporary wall system formed according to one embodiment of the present disclosed technology. The method 10 includes attaching a track to the floor of an area 20, attaching a first cover panel to a front surface of a plurality of insulation layers 30, attaching a second cover panel to a rear surface of the plurality of insulation layers to form a plurality of wall panels 40, attaching each of the plurality of wall panels to each other via a tongue and groove system to form a wall that spans the length of the track 50, and mounting the wall onto the track 60. In one embodiment, a second track is mounted on the wall to further stabilizing the wall. After the wall is mounted onto the track the temporary wall system 70 has been formed, as shown by FIGS. 3 and 4.

FIG. 2 shows a flow chart of a method of forming a temporary wall system according to another embodiment of the present disclosed technology. The method 100 includes attaching a track to a floor and/or ceiling of an area 110, attaching a first cover panel to a front surface of a plurality of insulation layers 120, attaching a second cover panel to a rear surface of the plurality of insulation layers to form a plurality of wall panels 130, mounting the plurality of wall panels on the track sequentially until the plurality of wall panels span the length of the track 140, and attaching the plurality of wall panels to each other via a tongue and groove system to form a wall 150. In one embodiment, a second track is mounted on the wall to further stabilizing the wall. After the plurality of wall panels have been attached to each other via the tongue and groove system the temporary wall system 70 has been formed, as shown by FIGS. 3 and 4.

Referring now to FIGS. 5-8, FIG. 5 shows an exploded view of the temporary wall system coming together according to a method of forming the temporary wall system in one embodiment of the present disclosed technology. FIG. 6 shows a cross-sectional view of the wall of the temporary wall system according to one embodiment of the present disclosed technology. FIG. 7 shows a close-up view of the tongue and groove system of the cover panels joined together to from the wall of the temporary wall system according to one embodiment of the present disclosed technology. FIG. 8 shows a side view of the track according to one embodiment of the present disclosed technology.

In one embodiment, the track 200 is attached to a floor and/or ceiling of an area by mounting the track 200 onto the floor and then fastening the track to the floor with fasteners 205, as shown in FIG. 5. The track 200 can be attached to the floor either horizontally, vertically, or perpendicularly relative to a wall of the area depending on where a user wants to erect the temporary wall. The fasteners 205 can include screws, bolts, hooks, hook & loop fastener, nails, glue, or other like suitable fasteners.

In some embodiments, the track 200 comprises an elongated track including a first side wall 210 and a second side wall 215. The first side wall 210 and the second side wall 215 define a rectangularly shaped groove 220 therebetween that extends longitudinally through the entirety of the elongated track. In embodiments, the track comprises a J-track, wherein the second side wall 215 includes a height greater than a height of the first side wall 210 for providing added support to the wall 225 and/or plurality of wall panels 230 mounted therein, as shown in FIG. 8. In one embodiment, the height of the second side wall 215 includes a height that is approximately two times greater than a height of the first side wall 210, as shown in FIG. 8. In some embodiments, the groove 220 includes a uniform cross section such that the groove 220 does not taper at any point along the elongated track, a shown in FIG. 5. In embodiments, the track 200 includes a width that is substantially equal to the width of the wall 225, such that the track 200 supports the wall 225 therein in an upstanding position, as shown in FIG. 6. In this way, no fasteners or the like are required to maintain the wall 225 within the track 200 in an upstanding position and the wall 225 may be assembled and disassembled more easily, and construction of the temporary wall requires less components. In one embodiment, the track comprises a metal track.

In some embodiments, the first cover panel 235 is attached to the front surface of each of the plurality of insulation layers 240 with a bulk spray adhesive 245, as shown in FIGS. 5 and 6. In one embodiment, the bulk spray adhesive 245 is sprayed on the entire front surface of each of the plurality of insulation layers 240 and then the first cover panel 235 is attached thereto, as shown in FIG. 5. In other embodiments, the bulk spray adhesive 245 is sprayed on only a portion of the front surface of each of the plurality of insulation layers 240. In some embodiments, the bulk spray adhesive 245 is a high strength cylinder spray adhesive. In embodiments, pressure is applied to the first cover panel 235 after mounted onto the front surface of an insulation layer of the plurality of insulation layers 240, such that the first cover panel 235 adheres better to the front surface of the insulation layer. In other embodiments, the first cover panel 235 is dried for a period of time so as to ensure adherence to the front surface of the plurality of insulation layers 240 and proper formation of the plurality of wall panels 230.

In some embodiments, the second cover panel 250 is also attached to the rear surface of each of the plurality of insulation layers 240 with a bulk spray adhesive 245, as shown in FIGS. 5 and 6. In one embodiment, the bulk spray adhesive 245 is sprayed on the entire rear surface of each of the plurality of insulation layers 240 and then the second cover panel 250 is attached thereto, as shown in FIG. 5. In other embodiments, the bulk spray adhesive 245 is sprayed on only a portion of the rear surface of each of the plurality of insulation layers 240. In some embodiments, the bulk spray adhesive 245 is a high strength cylinder spray adhesive. In embodiments, pressure is applied to the second cover panel 250 after mounted onto the rear surface of an insulation layer of the plurality of insulation layers 240, such that the second cover panel 250 adheres better to the rear surface of the insulation layer. In other embodiments, the second cover panel 250 is dried for a period of time so as to ensure adherence to the rear surface of the plurality of insulation layers 140 and proper formation of the plurality of wall panels 230. In one embodiment, the first cover panel 235 and the second cover panel 250 comprise a polyvinyl chloride (PVC) panel. The front surface is a first surface on a first side of the plurality of insulation layers and the rear surface is a second surface on a second opposing side of the plurality of insulations layers, such that the front and rear surfaces of the plurality of insulation layers oppose each other and face in opposite directions in embodiments of the disclosed technology.

In some embodiments, each of the plurality of insulation layers 240 comprises a thermal insulation board 255 comprising a rigid cellular polyisocyanurate foam core disposed coextensively between a first foil facer and a second foil facer, as shown in FIG. 7. In embodiments, the first foil facer defines the front surface of the plurality of insulation layers 240 and the second foil facer defines the rear surface of the plurality of insulation layers 240.

In some embodiments, the first cover panel 235 and the second cover panel 250 each comprise a first side including a tongue 260 extending along an edge of the first side and an opposing second side including a groove 265 extending along an edge of the second side, as shown in FIG. 7. The tongue 260 and groove 265 are complimentary in that they are configured to mate and fasten with each other when joined.

In one embodiment, the first cover panel 235 and the second cover panel 250 are attached to a respective insulation layer such that the first sides of the first and second cover panels 235, 250 are parallelly aligned on a first side of a respective insulation layer, while the second opposing sides of the first and second cover panels 235, 250 are parallelly aligned on a second side of the respective insulation layer, as shown in FIG. 7. Thus, the resultant wall panel formed by attachment of the first and second cover panels 235, 250 to a respective insulation layer includes a pair of tongues on a first side and a pair of grooves on a second opposing side. In this way, the plurality of wall panels 230 can be attached to one another by joining the tongues 260 of a first and second cover panel that are disposed on a first wall panel of the plurality of wall panels to the grooves 265 of a first and second cover panel that are disposed on a second separate wall panel of the plurality of wall panels 230. Joining the corresponding tongues 260 and grooves 265 of the plurality of wall panels forms the wall.

In another embodiment, the first cover panel 235 and the second cover panel 250 are attached to a respective insulation layer such that the first side of the first cover panel 235 and the second side of the second cover panel 250 are parallelly aligned on a first side of the respective insulation layer, while the second side of the first cover panel 235 and the first side of the second cover panel 250 are parallelly aligned on the second side of the respective insulation layer. Thus, each of the plurality of wall panels 230 has a tongue 260 and a groove 265 on a first side that are parallelly aligned and a tongue 260 and a groove 265 on a second opposing side that are parallelly aligned. In some embodiments, a second track 270 is mounted on the wall 225 to further secure the plurality of wall panels 230 to each other, as shown in FIGS. 5 and 6. In alternative embodiments, a cover plate 275 is mounted on the second track 270 to secure the second track 270 over the plurality of wall panels and further stabilize the wall 225 and resultant temporary wall system, as shown in FIGS. 5 and 6.

In embodiments, the temporary wall is formed first by attachment of the plurality of wall panels 50 and then is mounted onto the track by sliding the wall into the groove of track until the walls ends are coextensive with the tracks ends 60, as shown in FIGS. 1, 3 and 4. For example, in one embodiment, the wall is mounted into the groove of the track and then slid along the groove until the end of the track. The wall width is substantially equal to the groove width such that the wall friction fits inside of the groove, thereby requiring no fastener to secure the wall to the track and maintain the wall in an upstanding position.

In other embodiments, the wall is formed by first sliding the plurality of wall panels into the track in sequential fashion 140, and then joining them via the tongue and grooves on the track 150, as shown by FIG. 2-4. For example, in one embodiment, the plurality of wall panels are mounted into the groove of the track one by one, and then slid into the track such that all of the plurality of wall panels are disposed along the track. While on the track, the plurality of wall panels are joined to form the wall, such that the wall is coextensive with the track.

While the disclosed technology has been taught with specific reference to the above embodiments, a person having ordinary skill in the art will recognize that changes can be made in form and detail without departing from the spirit and the scope of the disclosed technology. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Combinations of any of the methods, systems, and devices described herein-above are also contemplated and within the scope of the disclosed technology. 

1. A method of forming a temporary wall system, comprising: attaching a track to a floor and/or ceiling of an area; attaching a first cover panel to a front surface of a plurality of insulation layers; attaching a second cover panel to a rear surface of the plurality of insulation layers to form a plurality of wall panels; attaching each of the plurality of wall panels to each other via a tongue and groove system to form a wall that spans the length of the track; and mounting the wall on the track; wherein the track includes a width substantially equal to the width of the wall, such that the track supports the wall therein in an upstanding position.
 2. The method of claim 1, wherein the track is a J-track and is attached to the floor and/or ceiling of an area by mounting the J-track onto the floor and/or ceiling and fastening the J-track with fasteners.
 3. The method of claim 2, wherein the first cover panel is attached to the front surface of each of the plurality of insulation layers with a bulk spray adhesive.
 4. The method of claim 3, wherein the bulk spray adhesive is sprayed on the entire front surface of each of the plurality of insulation layers prior to attachment of the first cover panel.
 5. The method of claim 3, wherein the second cover panel is attached to the rear surface of each of the plurality of insulation layers with a bulk spray adhesive.
 6. The method of claim 5, wherein the bulk spray adhesive is sprayed on the entire rear surface of each of the plurality of insulation layers prior to attachment of the second cover panel.
 7. The method of claim 5, wherein each of the plurality of insulation layers comprises a thermal insulation board including a rigid cellular polyisocyanurate foam core disposed between a first foil facer defining the front surface of insulation layer and a second foil facer defining the rear surface of the insulation layer.
 8. The method of claim 5, wherein the first cover panel and the second cover panel each comprise a first side including a tongue extending along an edge of the first side and an opposing second side including a groove extending along an edge of the second side, wherein the tongue and groove are complimentary so as to mate and fasten with each other.
 9. The method of claim 8, wherein the plurality of wall panels are attached to each other by: joining the tongue of a first side of a first cover panel and the groove of a second side of a first cover panel in sequential fashion; and joining the tongue of a first side of a second cover panel and the groove of a second side of a second cover panel in sequential fashion, wherein attachment of the plurality of wall panels forms a wall.
 10. The method of claim 9, wherein the wall is mounted on the track by sliding the wall into the track such that the wall is coextensive with the track.
 11. A method of forming the temporary wall system, comprising: attaching a track to a floor of an area; attaching a first cover panel to a front surface of a plurality of insulation layers; attaching a second cover panel to a rear surface of the plurality of insulation layers to form a plurality of wall panels; mounting the plurality of wall panels on the track sequentially until the plurality of wall panels span the length of the track; and attaching the plurality of wall panels to each other via a tongue and groove system to form a wall; wherein the track includes a width substantially equal to the width of each of the plurality of wall panels, such that the track supports each of the plurality of wall panels therein in an upstanding position.
 12. The method of claim 11, wherein the track is attached to the floor of an area by mounting the track onto the floor and fastening the track with fasteners.
 13. The method of claim 12, wherein the first cover panel is attached to the front surface of each of the plurality of insulation layers with a bulk spray adhesive.
 14. The method of claim 13, wherein the bulk spray adhesive is sprayed on the entire front surface of each of the plurality of insulation layers prior to attachment of the first cover panel.
 15. The method of claim 13, wherein the second cover panel is attached to the rear surface of each of the plurality of insulation layers with a bulk spray adhesive.
 16. The method of claim 15, wherein the bulk spray adhesive is sprayed on the entire rear surface of each of the plurality of insulation layers prior to attachment of the second cover panel.
 17. The method of claim 15, wherein each of the plurality of insulation layers comprises a thermal insulation board including a rigid cellular polyisocyanurate foam core disposed between a first foil facer defining the front surface of insulation layer and a second foil facer defining the rear surface of the insulation layer.
 18. The method of claim 15, wherein the plurality of wall panels are mounted on the track by sliding each of the plurality of wall panels into the track until the plurality of wall panels are coextensive with the track.
 19. The method of claim 18, wherein the first cover panel and the second cover panel each comprise a first side including a tongue extending along an edge of the first side and an opposing second side including a groove extending along an edge of the second side, wherein the tongue and groove are complimentary so as to mate and fasten with each other.
 20. The method of claim 19, wherein the plurality of wall panels are attached to each other by: joining the tongue of a first side of a first cover panel and the groove of a second side of a first cover panel; and joining the tongue of a first side of a second cover panel and the groove of a second side of a second cover panel; wherein attachment of the plurality of wall panels forms a wall. 